Composite  laminate for a thermal and acoustic insulation blanket

ABSTRACT

A multilayer laminate for use as a flame barrier in an aircraft comprising (i) a polymeric film layer capable of withstanding a temperature of at least 200 C for at least 10 min, (ii) an adhesive layer having an areal weight of from 2 to 40 gsm capable of activation at a temperature of from 75 to 200 degrees C., (iii) an inorganic refractory layer, and (iv) aramid paper comprising from 50 to 90 weight percent of aramid fibers and from 10 to 50 weight percent of meta-aramid binder wherein the inorganic refractory layer of (iii) comprises platelets in an amount of at least 85% by weight with a dry areal weight of 15 to 50 gsm and a residual moisture content of no greater than 10 percent by weight.

BACKGROUND OF THE INVENTION

This application is a continuation of application Ser. No. 13/325,804filed on Dec. 14, 2011 which is a continuation in part of applicationSer. No. 12/759,741 filed on Apr. 14, 2010 which claims priority fromprovisional filing application No. 61/171163 filed on Apr. 21, 2009.

1. Field of Invention

This invention pertains to a composite laminate having flame resistantproperties. The invention also covers use of the composite laminate in athermal and acoustic blanket as may be found in an aircraft fuselage ora turbine engine compartment.

2. Background of the Invention

U.S. Pat. No. 6,322,022 to Fay et al. discloses burnthrough resistantsystems for transportation especially aircraft.

U.S. Pat. No. 6,670,291 to Tomkins and Vogel-Martin describes a laminatesheet material for fire barrier layer applications.

There remains an ongoing need for thermal and acoustic blankets foraircraft structures having reduced weight and improved resistance toflame spread.

SUMMARY OF INVENTION

This invention is directed to a multilayer laminate for use as a flamebarrier in an aircraft comprising:

-   -   (i) a polymeric film layer capable of withstanding a temperature        of at least 200 C for at least 10 min,    -   (ii) an adhesive layer having an areal weight of from 2 to 40        gsm capable of activation at a temperature of from 75 to 200        degrees C.,    -   (iii) an inorganic refractory layer, and    -   (iv) aramid paper comprising from 50 to 90 weight percent of        aramid fibers and from 10 to 50 weight percent of meta-aramid        binder;        -   wherein the inorganic refractory layer of (iii) comprises            platelets in an amount of at least 85% by weight with a dry            areal weight of 15 to 50 gsm and a residual moisture content            of no greater than 10 percent by weight.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic cross section through a composite laminate of thisinvention.

FIG. 2 is a cross section of a thermal and acoustic blanket comprising acomposite flame barrier laminate of this invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a section through a composite laminate 10 comprising apolymeric film layer 11, an adhesive layer 12, an inorganic refractorylayer 13 and an aramid paper layer 14.

Polymeric Film Layer

The polymeric film layer must be capable of withstanding a temperatureof at least 200 C for at least 10 min. The film layer may be a thermosetor thermoplastic material. A thermoplastic film is preferred.

Preferably the film layer should have a UL 94 flame classification ofV-0. UL 94 flame classification is an Underwriters Laboratory test, TheStandard for Flammability of Plastic Materials for Parts in Devices andAppliances, which measures a material's tendency either to extinguish orto spread the flame once the specimen has been ignited. V-0 indicatesthat the material is tested in a vertical position and self-extinguishedwithin ten seconds after the ignition source is removed.

A further requirement of the film layer is that it should have athickness in the range of from 4 to 30 micrometers. More preferably thethickness range should be from 5 to 15 micrometers and most preferablyin the range from 5 to 7 micrometers. The film layer provides mechanicalstrength and stiffness to the laminate.

Suitable film layer materials are polyketone, polyimide, polysulfone,polyarylene sulfide, fluoropolymers, liquid crystal polymers andpolycarbonate. Examples of polyketone are polyetheretherketone (PEEK)and polyetherketoneketone (PEKK). Polyethersulfone and polyphenylsulfoneare examples of polysulfone. Poly(p-phenylene sulfide is a suitablepolyarylene sulfide for use in this invention. Polyvinylfluoride (PVF)and polyvinylidinefluoride (PVDF) are examples of fluoropolymers. Asuitable fluoropolymer is available from E.I. du Pont de Nemours,Wilmington, Del. under the tradename Tedlar. Polyarylate is an exampleof a suitable liquid crystal polymer. Some of these films may also becoated with a second polymeric material. For example, a polyimide film,Kapton®, may be coated with fluorinated ethylene propylene, FEP and usedin this invention.

In a preferred embodiment, the film layer is PEEK or PEKK.

The surface of the film layer may optionally be treated to improveadhesion with another substrate such as an adhesive. Suitable surfacetreatment methods include, but are not limited to, corona etching andwashing with coupling agents such as ammonium, phosphonium or sulfoniumsalts.

In some embodiments, the film layer is metalized on at least onesurface. In some embodiments, the metalized surface is in contact withthe adhesive layer.

Adhesive Layer

The adhesive layer is located between the polymeric film layer and therefractory layer. It is shown at 12 in FIG. 1.

The adhesive layer may be a thermoplastic or thermoset resin. Thermosetresins include epoxy, epoxy novolac, phenolic, polyurethane, andpolyimide. Thermoplastic resins include polyester, polyetherketone,polyetheretherketone, polyetherketoneketone, polyethersulfone, andpolyolefin. Thermoplastic resins are preferred.

One of the objectives for having a high temperature polymeric filmadhesively bonded to a refractory layer is to provide mechanicalreinforcement and protection to the overall composite laminate duringmanufacturing, installation and service.

To prevent possible damage from mechanical stressing exerted by ashrinking/melting/disintegrating polymeric film on an inorganicrefractory film-like layer it is preferred that inter-ply bond of thecomposite laminate would fail (i.e. release/melt/soften) in the earlystage of the flame exposure causing internal de-bonding of the compositelaminate (i.e delamination of the refractory layer from the polymericfilm) before the polymeric film starts disintegrating. Due to theirrelatively low activation temperatures, thermoplastic adhesives are apreferred choice over thermoset adhesives for this application.

The adhesive layer may optionally contain up to 40 weight percent of aflame retardant ingredient. Suitable flame retardant ingredients includeantimony trioxide, halogenated flame retardants includingtetrabromobisphenol A, polybrominated biphenyls, Penta-, Octa-,Deca-brominated diphenyl ether (oxide) and hexabromocyclododecane.Phosphorus containing flame retardants are also widely used.

The adhesive must be capable of activation at a temperature in the rangeof 75 to 200 degrees C. In some embodiments, the activation range isfrom 120 to 140 degrees C. By activation we mean that for a thermosetresin, the resin must bond to the polymeric film layer and therefractory layer within the specified temperature range. For athermoplastic resin, activation means that the resin softens and flowssufficiently to bond to the polymeric film layer and the refractorylayer. The adhesive bond between the inorganic refractory layer and thepolymeric film is at least 0.25 lb/in. In some embodiments, the adhesivebond between the inorganic refractory layer and the polymeric film is atleast 0.8 lb/in.

The adhesive layer weighs from 2 to 40 gsm. In some embodiments theadhesive layer weighs from 3 to 15 gsm or even from 5 to 10 gsm. If theadhesive weight is below 2 gsm, the bond strength will be too weak. Ifthe adhesive weight is greater than 40 gsm, unnecessary weight will beadded.

Refractory Layer

The inorganic refractory layer is on the opposite side of the adhesivelayer from the polymeric film layer as is shown at 13 in FIG. 1.

The refractory layer has a dry areal weight of from 15 to 50 gsm and aresidual moisture content of no greater than 10 percent by weight, Insome embodiments, the refractory layer has a dry areal weight of from 20to 35 gsm and a residual moisture content of no greater than 3 percentby weight.

The refractory layer comprises platelets. Preferably at least 85% of thelayer comprises platelets, more preferably at least 90% and mostpreferably at least 95%. In some embodiments, platelets comprise 100% ofthe layer. The refractory layer may comprise some residual dispersantarising from incomplete drying of the platelet dispersion duringmanufacture.

In some embodiments, the refractory layer has a thickness of from 7.0 to76 micrometers and more preferably from 7.0 to 50 micrometers. In someembodiments, the refractory layer has a UL 94 flame classification ofV-0. The function of the refractory layer, in which adjacent plateletsoverlap, is to provide a flame and hot gas impermeable barrier. Theinorganic platelets may be clay, such as montmorillonite, vermiculite,mica, talc and combinations thereof. Preferably, the inorganic oxideplatelets are stable (i.e., do not burn, melt or decompose) at about 600degrees C., more preferably at about 800 degrees C. and most preferablyat about 1000 degrees C. Vermiculite is a preferred platelet material.Vermiculite is a hydrated magnesium aluminosilicate micaceous mineralfound in nature as a multilayer crystal. Vermiculite typically comprisesby (dry) weight, on a theoretical oxide basis, about 38-46% SiO₂, about16-24% MgO, about 11-16% Al₂O₃, about 8-13% Fe₂O₃ and the remaindergenerally oxides of K, Ca, Ti, Mn, Cr, Na, and Ba. “Exfoliated”vermiculite refers to vermiculite that has been treated, chemically orwith heat, to expand and separate the layers of the crystal, yieldinghigh aspect ratio vermiculite platelets. Suitable vermiculite materialsare available from W. R. Grace of Cambridge, Mass., under the tradedesignations MicroLite 963 and MicroLite HTS-XE.

The thickness of an individual platelet typically ranges from about 5Angstroms to about 5,000 Angstroms more preferably from about 10Angstroms to about 4,200 Angstroms. The mean value of the maximum widthof a platelet typically ranges from about 10,000 Angstroms to about30,000 Angstroms The aspect ratio of an individual platelet typicallyranges from 100 to 20,000.

In some embodiments of this invention, the inorganic platelet layer isreinforced by a lightweight open weave fabric scrim either laid onto asingle platelet layer or placed between two layers of platelets so as toprovide additional mechanical strength to the layer. The scrim can bemade from natural, organic or inorganic fibers with glass, cotton, nylonor polyester being typical examples. A glass fiber scrim is particularlypreferred. The scrim may be a woven or knit structure and has a typicalareal weight not exceeding 40 grams per square meter.

In some embodiments, the refractory layer is perforated to enhancebonding to the adhesive layer. With a perforated refractory layer, theadhesive bond between the refractory layer and the polymeric film is atleast 1.0 lb/in. The extent of perforation is determined byexperimentation for each laminate assembly. In order to preventcompromising flame barrier properties, an individual perforation shouldnot exceed 2 millimeters in maximum dimension. In a preferableembodiment, individual perforations should be spaced at least 10millimeters apart. The shape of the perforations is not critical,Suitable perforations include circles, squares, rectangles, ovals andchevrons.

A refractory layer comprising platelets as herein described provides anonporous, flexible, film-like sheet or coating. The platelet layer isalso thin, dense and has a very smooth and tough surface, attributesthat assist in the heat sealing process when the laminate comprising therefractory layer is used in a thermal blanket. A refractory layercomprising ceramic fibers is much more porous, brittle, and friable.

In a preferred embodiment, the refractory layer further comprisescations arising from contact, at a temperature of from 10 to 50 degreesC., with an aqueous cationic rich solution at a cation concentration offrom 0.25 to 2N. The contact with the cationic solution occurs prior toassembling the refractory layer into the composite laminate. Thiscationic treatment provides enhanced stability to the refractory layeron exposure to fluids.

Aramid Paper Layer

In one embodiment, the aramid paper comprises from 50 to 90 weightpercent of aramid fibers and from 10 to 50 weight percent of binder. Apreferred binder is meta-aramid.

The thickness of the paper used in this invention is dependent upon theend use or desired properties of the laminate but is typically from 3 to20 mils (75 to 500 micrometers) thick. In some embodiments, the basisweight of the paper is from 0.5 to 6 ounces per square yard (15 to 200grams per square meter).

The aramid fibers of the paper can be in the form of floc, pulp, or acombination of thereof. As employed herein the term aramid means apolyamide wherein at least 85% of the amide (—CONH—) linkages areattached directly to two aromatic rings. Additives can be used with thearamid. In fact, it has been found that up to as much as 10 percent, byweight, of other polymeric material can be blended with the aramid orthat copolymers can be used having as much as 10 percent of otherdiamine substituted for the diamine of the aramid or as much as 10percent of other diacid chloride substituted for the diacid chloride ofthe aramid.

Floc is generally made by cutting continuous spun filaments intospecific-length pieces. If the floc length is less than 2 millimeters,it is generally too short to provide a paper with adequate strength; ifthe floc length is more than 25 millimeters, it is very difficult toform uniform wet-laid webs. Floc having a diameter of less than 5micrometers, and especially less than 3 micrometers, is difficult toproduce with adequate cross sectional uniformity and reproducibility; ifthe floc diameter is more than 20 micrometers, it is very difficult toform uniform papers of light to medium basis weights.

The term “pulp”, as used herein, means particles of fibrous materialhaving a stalk and fibrils extending generally therefrom, wherein thestalk is generally columnar and 10 to 50 micrometers in diameter and thefibrils are fine, hair-like members generally attached to the stalkmeasuring only a fraction of a micrometer or a few micrometers indiameter and 10 to 100 micrometers long. Aramid fiber floc is of asimilar length to carbon fiber floc. Both meta and para aramid fibersare suitable and are available from E.I. DuPont de Nemours, Richmond,Va. under the tradenames Kevlar® and Nomex® and from Teijin Twaron,Conyers, Ga. under the tradename Twaron®.

A preferred pulp material is p-aramid. However a blend of p-aramid withother synthetic or natural fibers such as liquid crystal polyester,polyareneazole, meta-aramid, and cellulose can be utilized. Oneillustrative process for making aramid pulp is disclosed in U.S. Pat.No. 5,084,136 to Haines et al.

Different thermoset and thermoplastic resins can be used as a polymericbinder in the paper of this invention. These resins can be supplied inthe form of fibrids, flakes, powder, and floc. The term “fibrids” asused herein, means a very finely-divided polymer product of small,filmy, essentially two-dimensional, particles known having a length andwidth of 100 to 1000 micrometers and a thickness of 0.1 to 1 micrometer.Preferable types of binder resins are aramids, polyimides, phenolics,and epoxies. However, other types of the resins can also be used.

Fibrids are typically made by streaming a polymer solution into acoagulating bath of liquid that is immiscible with the solvent of thesolution. The stream of polymer solution is subjected to strenuousshearing forces and turbulence as the polymer is coagulated. The fibridmaterial of this invention can be selected from meta or para-aramid orblends thereof. More preferably, the fibrid is a meta-aramid.

The paper can include small amounts of inorganic particles includingmica, vermiculite, and the like; the addition of these performanceenhancing additives being to impart properties such as improved fireresistance, thermal conductivity, dimensional stability, and the like tothe paper and the final laminate.

In one preferred embodiment, the fiber and the polymer binder in theform of fibrids can be slurried together to form a mix that is convertedto paper on a wire screen or belt. Reference is made to U.S. Pat. No.4,698,267 and U.S. Pat. No. 4,729,921 to Tokarsky; U.S. Pat. No.5,026,456 to Hesler et al.; U.S. Pat. No. 5,223,094 and U.S. Pat. No.5,314,742 to Kirayoglu et al for illustrative processes for formingpapers from aramid fibers and aramid fibrids.

Once the paper is formed, it may be calendered to the desired voidcontent/apparent density.

Flame Barrier

The composite laminate as described above may be used as a flame barrierlayer. Flame barrier layers find use in applications in vehicles orbuilding structures such as aircraft, trains, boats and offshore rigswhere the fire barrier layers may be found in ceiling, sidewall andfloor panels. For aircraft, other uses are in cargo liners and thermalacoustic blankets.

Thermal Acoustic Blanket

The flame barrier as described above may be used as a component in athermal insulation and acoustic blanket. An example of such a blanket isdescribed in U.S. Patent Application publication No. 2007/0155265 toAnderson. FIGS. 2 and 3 of this publication show at 16 a flame-retardantbarrier layer. The flame barrier layer of this invention could replacethe flame barrier layers described in the Anderson publication.

FIG. 2 depicts at 20 another embodiment in which a thermal and acousticblanket 20 comprises an inorganic or organic core of fibrous batting 15having a first outer surface 15 a and a second outer surface 15 b. Thecore has a self-extinguishing time no greater than 10 seconds and amaximum burn length of no greater than 102 mm when tested in accordancewith BSS7230 Method F1. A composite laminate 10 as previously describedand as depicted in FIG. 1 covers the first outer surface of the core andpartially covers the second outer surface. The laminate is positionedover the core such that the aramid paper component 14 is adjacent to thecore and the polymeric film component 11 is furthest away from the core.A high temperature resistant backing film 16 covers that portion of thecore not covered by the laminate. The backing film 16 overlaps thelaminate and is bonded to the polymeric film component 11 of thelaminate in the region of the overlap.

In a further embodiment, the surface of the aramid paper not in contactwith the refractory layer is bonded to a scrim reinforcement fabric witha fire retardant (FR) heat seal adhesive. In this structure, thereinforcement fabric covers the first outer surface of the core andpartially covers the second the outer surface. Suitable scrimreinforcement materials include, but are not limited to, nylon, aramidand fiberglass.

The high temperature resistant polymeric backing film 16 may bethermoset or thermoplastic. Thermoplastic films are preferred.Preferably the film is inherently flame resistant that is, it will notpropagate fire when exposed to flame. Suitable polymers for the filminclude polyketone, polyimide, polysulfone, polyarylene sulfide,fluoropolymers, liquid crystal polymers and polycarbonate. Examples ofpolyketone are polyetheretherketone (PEEK) and polyetherketoneketone(PEKK). Polyethersulfone and polyphenylsulfone are examples ofpolysulfone. Poly(p-phenylene sulfide is a suitable polyarylene sulfidefor use in this invention. Polyvinylfluoride (PVF) andpolyvinylidinefluoride (PVDF) are examples of fluoropolymers. A suitablefluoropolymer is available from E.I. du Pont de Nemours, Wilmington,Del. under the tradename Tedlar. Polyarylate is an example of a suitableliquid crystal polymer. Some of these films may also be coated with asecond polymeric material. For example, a polyimide film, Kapton®, maybe coated with fluorinated ethylene propylene, FEP and used in thisinvention.

In a one embodiment, the film layer is PEEK or PEKK. In a furtherembodiment, the high temperature polymeric backing film is reinforced bya scrim fabric in a similar manner to the aramid paper such that thereinforcement fabric partially covers the second the outer surface ofthe core. Suitable scrim reinforcement materials include, but are notlimited to, nylon, aramid and fiberglass.

The blanket is placed against the interior skin of an aircraft fuselagewith the surface of the blanket comprising the backing film 16 furthestaway from the fuselage.

It is a requirement for the composite flame barrier laminate 10 to meetthe following flammability requirements. In a vertical test (60 secondsignition), when tested according to Federal Aviation Regulation, Section25, Appendix F, Part1, the composite flame barrier laminate 10 must beself- extinguishing in no greater than 10 seconds and must have amaximum burn length of no greater than 102 mm. In a 45 Degree AngleTest, when tested according to BSS7230, the self-extinguishing time mustbe no greater than 5 seconds and the afterglow no greater than 10seconds.

The core may be foam or an organic or inorganic fibrous material. Asuitable foam material is polyimide available under the tradenameINSULMIDE from Johns Manville Insulations Group, Denver, Colo. orSOLIMIDE from Inspec Foams, Allen, Tex. Suitable non-metallic fibersinclude, but are not limited to, glass fibers, aramid fibers,crystalline ceramic oxide (including quartz) fibers, silicon nitridefibers, silicon carbide fibers, oxidized polyacrylonitrile fibers,carbon fibers, and combinations thereof.

Glass fiber is a preferred material with E-glass, a low alkaliborosilicate glass, being particularly suitable. Ceramic oxide materialsare typically metal oxides that have been consolidated by the action ofheat. Ceramic oxide fibers generally refer to a class of fiberstypically containing one or more oxides of aluminum, silicon, and boron.Many other additives may also be present (e.g., oxides of sodium,calcium, magnesium, and phosphorus) within the fibers, although thefibers include primarily metal oxides. Typically, the ceramic oxidefibers are crystalline ceramics and/or a mixture of crystalline ceramicand glass (i.e., a fiber that contains both crystalline ceramic andglass phases). Preferred ceramic oxide fibers are aluminosilicate,aluminoborosilicate, and alumina fibers, and may be in the form of yarnsor in the form of staple fibers. The preferred form of non-metallicfiber is a batting which is a soft bulky assembly of fibers, usuallycarded. Battings have a typical density range of from 5.5 to 24.0kg./m³. Suitable glass batting is available under the MICROLITE AAtradename from Johns Manville OEM Insulations Division, Denver, Colo.The core may comprise more than one layer of material. The materials indifferent layers of the core need not be the same.

Test Methods

The 4-layer composite laminates were subjected to a flame test thatreplicated the temperature and air mass flux test conditions of testmethod FAA FAR 25.856(b), App. F, Part VII. Somewhat lower heat flux wascompensated with a higher air mass flux to replicate a requiredthermo-mechanical stress level to be exerted on the composite flamebarrier laminates during the burn-through test.

EXAMPLES

All parts and percentages are by weight unless otherwise indicated. Alltemperatures are in degrees C. unless otherwise indicated.

Inorganic Refractory Material

The inorganic refractory material used in all the examples wasvermiculite. The vermiculite grade was a high solids version of anaqueous dispersion of Microlite® 963 having an as supplied solidscontent of 7.5 percent. The dispersion was obtained from W. R. Grace andCo, Cambridge, Mass. The vermiculite dispersion used in all the Exampleswas concentrated to a solids content of 10.6 weight percent.

Aramid Paper

The paper used in all the examples was T413 grade Nomex® from DuPont.The paper had a basis weight of 1.23 oz/sq. yd., an average thickness of4.9 mil, a density of 0.34 ccm, a Gurley Air Resistance of 316 sec/100cc, 20 oz. cyl., a smoothness of 325 Sheffield units, a dry tensilestrength of 10.7 lb./in. in a first (machine) direction and 5.5 lb./in.in a second (cross) direction. The wet tensile strength was 5.1 lb./in.in a first (machine) direction and 2.95 lb./in. in a second (cross)direction.

Polymeric Film

The polymeric film used in all examples was a 6 micron thickpolyetheretherketone (PEKK) film grade DS-E obtained from CytecIndustries, Woodland Park, N.J.

Adhesive

The adhesive used in all examples was Bostik LADH 402, a solvent-basedpolyamide fire retardant thermoplastic liquid adhesive obtained fromBostik Inc., Wauwatosa, Wis.

Lamination Equipment

For all Examples, a flat-bed double-belt laminator with a Teflon coatedfiberglass belt was used to form the composite laminates. The laminationtemperatures in the 9 foot long pre-nip heating section were 70 to 90degrees in zone 1, 90 to 110 degrees in zone 2 and 130 to 150 degrees inzone 3.

The lamination temp in the 3 foot long post-nip cooling section was 50to 70 degrees in zone 4.

The force applied by the belt on a sample size of 400 square centimeterswas 5 kN. The machine line speed was 2 m/min.

Preparation of the Inorganic Refractory Layer on Aramid Paper

Vermiculite dispersion concentrated to a solids content of 10.6% weightpercent was coated on the T413 paper using a slot die coating system toform a refractory layer on the paper.

The coated paper was dried for 15 minutes in an air flotation oven at atemperature not exceeding 110 degrees C. until the inorganic refractorylayer had moisture content below 5%. Differential drying temperatureswere applied to the top (vermiculite side) and the bottom (release paperside). The drying profile on the top side was 5 minutes at 49 degrees, 5minutes at 60 degrees and 5 minutes at 71 degrees. The drying on thebottom side was maintained for 15 minutes at 99 degrees. The refractorylayer had a dry coat weight of 37 gsm. The two layer composite of paperand refractory layer was wound up on a roll.

Example 1

In this example, the 2-layer flame barrier composite comprising therefractory layer on an aramid paper was adhesively bonded to PEKK filmto form a 4-layer composite laminate.

The adhesive was deposited on the surface of the PEKK film using aGardco Adjustable Micrometer “Microm II” Film Applicator. Afterdeposition, the coated film was dried in a conventional oven at 80degrees for 10 minutes to allow the solvent in the adhesive toevaporate. The dry weight of the adhesive deposited on the polymericfilm was 8 gsm.

The dry adhesive coated film was then bonded to the refractory layer onan aramid paper in the double-belt laminator, with the dry adhesivecontacting the exposed refractory surface to form 4-layer compositelaminate.

The 4-layer composite was subjected to the flame test. When exposed to aflame on the polymeric film side, the sample showed a good resistance toflame propagation, with inorganic refractory layer acting as aneffective flame barrier. The Nomex® paper prevented propagation of thefire.

Example 2

This was as Example 1 except that, after coating and drying, a 2-layercomposite comprising inorganic refractory layer on an aramid paper wastreated, at ambient conditions, with an aqueous cationic rich solution.

The coated release paper was immersed for one minute in a cation richsolution of sodium chloride dispersed in water at 0.5N concentrationthen air dried at 24 degrees C. for 2 minutes followed by additionaldrying for 30 minutes inside a conventional oven heated to 80 degrees C.

Once dried to about 3% moisture content, the cation treated material wasremoved from the oven. Excess dry sodium chloride that had accumulatedon the outer surfaces of the refractory layer and the release paper wascarefully wiped off with a dry soft cloth.

The cation treated 2-layer composite comprising refractory layer on anaramid paper was then adhesively bonded to PEKK film to form a 4-layerlaminate in the same manner as Example 1.

When compared to the non-cation treated refractory layer of Example 1,the cation treated layer showed a significantly improved stability whenexposed to either high humidity conditions for a prolonged time such as120 hours inside an aging chamber at 80 degrees C. and 90% RH or afterimmersion in water for at least 10 minutes. Other findings were similarto those of Example 1.

Example 3

This was as Example 2 except that potassium chloride was used to makethe aqueous cationic rich solution. The findings were the same as forExample 2,

What is claimed is:
 1. A multilayer laminate for use as a flame barrierin an aircraft comprising (i) a polymeric film layer capable ofwithstanding a temperature of at least 200 C for at least 10 min, (ii)an adhesive layer having an areal weight of from 2 to 40 gsm capable ofactivation at a temperature of from 75 to 200 degrees C., (iii) aninorganic refractory layer, and (iv) aramid paper comprising from 50 to90 weight percent of aramid fibers and from 10 to 50 weight percent ofmeta-aramid binder; wherein the inorganic refractory layer of (iii)comprises platelets in an amount of at least 85% by weight with a dryareal weight of 15 to 50 gsm and a residual moisture content of nogreater than 10 percent by weight.
 2. The laminate of claim 1 whereinthe inorganic refractory layer comprises vermiculite.
 3. The laminate ofclaim 1 wherein the inorganic refractory layer comprises platelets in anamount of at least 90% by weight with a dry areal weight of 15 to 50 gsmand a residual moisture content of no greater than 10 percent by weight.4. The laminate of claim 1 wherein the inorganic refractory layer isperforated.
 5. The laminate of claim 1 wherein the polymeric film layeris a fluoropolymer, polyimide, polyetheretherketone, orpolyetherketoneketone.
 6. The laminate of claim 1 wherein the polymericfilm layer is metalized on at least one surface.
 7. The laminate ofclaim 1 wherein the adhesive layer contains up to 40 weight percent of aflame retardant ingredient.
 8. The laminate of claim 1 wherein theadhesion bond between inorganic refractory layer and the polymeric filmis at least 0.25 lb/in.
 9. The laminate of claim 1 wherein the inorganicrefractory layer has a dry areal weight of from 20 to 35 gsm.
 10. Thelaminate of claim 1 wherein the inorganic refractory layer has amoisture content of no greater than 3%.
 11. The laminate of claim 3wherein the inorganic refractory layer comprises platelets in an amountof at least 95% by weight with a dry areal weight of 15 to 50 gsm and aresidual moisture content of no greater than 10 percent by weight. 12.The laminate of claim 8 wherein the adhesion bond between inorganicrefractory layer and the polymeric film is at least 0.8 lb/in.
 13. Athermal acoustic blanket for an aircraft comprising (i) a core offibrous batting having first and second outer surfaces, (ii) amultilayer laminate covering the first outer surface of the core andpartially covering the second outer surface of the core, and (iii) apolymeric backing film covering the portion of the second outer surfaceof the core not covered by the multilayer laminate, wherein, thepolymeric backing film overlaps and is bonded to the multilayerlaminate, the polymeric backing film can withstand a temperature of atleast 200 C for at least 10 min, and the core has a self-extinguishingtime no greater than 10 seconds and a maximum burn length of no greaterthan 102 mm when tested in accordance with BSS7230 Method F1, whereinthe multilayer laminate of (ii) comprises: (a) a polymeric film layercapable of withstanding a temperature of at least 200 C for at least 10min, (b) an adhesive layer having an dry areal weight of from 2 to 40gsm capable of activation at a temperature of from 75 to 200 degrees C.,(c) an inorganic refractory layer of platelets, and (d) aramid papercomprising from 50 to 90 weight percent of aramid fibers and from 10 to50 weight percent of meta-aramid binder.